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Generac Power Systems 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, 004125-1, 004126-1, 004127-1 Owner's Manual

Liquid-cooled, prepackaged standby generator.
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POWER SYSTEMS, INC.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas)
004090-2
004091-2
004092-2
004093-2
004094-2
004095-2
004096-2
004097-2
004474-0 (w/TS)
(Liquid Propane Vapor)
004124-1
004125-1
004126-1
004127-1
004128-1
004130-1
004131-1
004475-0 (w/TS)
®

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   Also See for Generac Power Systems 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, 004125-1, 004126-1, 004127-1

   Related Manuals for Generac Power Systems 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, 004125-1, 004126-1, 004127-1

   Summary of Contents for Generac Power Systems 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, 004125-1, 004126-1, 004127-1

  • Page 1

    POWER SYSTEMS, INC. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers (Natural Gas) 004090-2 004092-2 004094-2 004096-2 004474-0 (w/TS) (Liquid Propane Vapor) 004124-1 004126-1 004128-1 004131-1 004475-0 (w/TS) ® 004091-2 004093-2 004095-2 004097-2 004125-1 004127-1...

  • Page 2

    INTRODUCTION Thank you for purchasing this model of the standby gen- erator set product line by Generac Power Systems. Every effort was expended to make sure that the infor- mation and instructions in this manual were both accu- rate and current at the time the manual was written.

  • Page 3: Table Of Contents

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators INTRODUCTION SAFETY RULES ...2 Section 1 GENERAL INFORMATION ...4 Generator ...4 Automatic System Operation ...4 Generator AC Connection Systems ...4 Main Circuit Breaker...5 Generator Fuel System ...5 Engine Protective Devices ...5 Unpacking...6 Generator Specifications ...6 Lifting the Generator ...7...

  • Page 4: Safety Rules

    Important Safety Instructions Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.

  • Page 5: Electrical Hazards

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up.

  • Page 6: Section 1 - General Information

    Section 1 - General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators GENERATOR This equipment is an water-cooled, engine-driven gen- erator set. The generator is designed to supply electrical power that operates critical electrical loads during util- ity power failure.

  • Page 7: Main Circuit Breaker

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Figure 3 represents a single-phase, 3-wire generator AC connection system. The stator assembly in this system consists of a pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 120 volts AC, 60 Hertz.

  • Page 8: Unpacking

    Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators LOW COOLANT LEVEL SWITCH: Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown.

  • Page 9: Lifting The Generator

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators INSPECTION: After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix his signature under the consignor’s memo of loss or damage.

  • Page 10: Before Installation

    Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators BEFORE INSTALLATION Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation Method”...

  • Page 11: Standby Generator Installation

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch (such as the Generac “GTS” type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating.

  • Page 12: Emergency Circuit Isolation Method

    Section 2 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping elec- trical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, during util- ity power outages, you might consider using the emer- gency circuit isolation method.

  • Page 13: Preparation Before Start-up

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators an explosion. Such an explosion can shatter the bat- tery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

  • Page 14: Section 3 - Operation

    Section 3 — Operation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Fuel System Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according code.

  • Page 15: Control Console Components

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators CONTROL CONSOLE COMPONENTS The components of a water-cooled generator control console (Figure 8) are as follows: Figure 8 - Water-Cooled Generator Panel AC VOLTMETER: The voltmeter displays generator AC output voltage dur- ing operation.

  • Page 16: Retransfer And Shutdown

    Section 3 — Operation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators RETRANSFER AND SHUTDOWN When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as follows: •...

  • Page 17: Section 3 - Maintenance

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS 1.Check battery state of charge and condition. 2.Inspect and test fuel system. 3.Check transfer switch. 4.Inspect exhaust system. 5.Check engine ignition system.

  • Page 18: Maintenance Owner/operator Can Perform

    Section 3 — Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators MAINTENANCE OWNER/OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to “Checking Fluid Levels” on page 15. CHECK BATTERY • Check battery fluid level each week as outlined under “Check Fluid Levels”.

  • Page 19: Miscellaneous Maintenance

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators CAUTION: After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIP- STICK “ADD” MARK. 7.Start engine and check for oil leaks. COOLANT CHANGE Every year, have Authorized Service Facility drain, flush and refill the cooling system.

  • Page 20: Troubleshooting

    Section 4 — Troubleshooting Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won’t crank. 1. 30 amp fuse blown. 2. Loose or corroded or defective 3. Defective starter contactor. 4. Defective starter motor. 5.

  • Page 21: Notes

    Section 5 - Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Generac Power Systems, Inc. 19 ®...

  • Page 22: Wiring Diagrams And Schematics

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803C FUSE 20 Generac Power Systems, Inc. ®...

  • Page 23

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802A Generac Power Systems, Inc. 21 ®...

  • Page 24

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A2804C 22 Generac Power Systems, Inc. ®...

  • Page 25

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2805B Generac Power Systems, Inc. 23 ®...

  • Page 26

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A7176A 24 Generac Power Systems, Inc. ®...

  • Page 27

    Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A7182A Generac Power Systems, Inc. 25 ®...

  • Page 28: Exploded Views And Parts Lists

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1404A 26 Generac Power Systems, Inc. ®...

  • Page 29

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. DESCRIPTION A2110 1/4"-20-1/2" FASTENER A2115 1/4" NYLON WASHER A3133A SLIP HINGE, MALE L.H. A3133B SLIP HINGE, FEMALE L.H. A3133C SLIP HINGE, MALE R.H. A3133D SLIP HINGE, FEMALE R.H.

  • Page 30

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel — Drawing No. 0C8847B 28 Generac Power Systems, Inc. ®...

  • Page 31

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. DESCRIPTION 0C5077 SUPPORT, CONTROL PANEL L.H. 075589 BRACKET, VOLTAGE REGULATOR 0A1775 CONTRLPANEL-BACK 0C5078 SUPPORT CONTROL PANEL R.H. 0C4224A SILKSCREEN, PANEL (SAE) 057073 BLOCK JUNCTION 3/8-16 022985 WASHER FLAT #6 ZINC 081988...

  • Page 32

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1406B 30 Generac Power Systems, Inc. ®...

  • Page 33

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. 0A4822 0A5734 0A6237 0A6238 084918 050967 12" 057823 099502 083709 042568 022097 049813 022473 084427 050967 18" 075443 056892 0A6284 0A6258 029032 031669 060035 022127 022145 022129...

  • Page 34

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1405A ITEM PART NO. QTY. DESCRIPTION 0A9955 BASE MOUNTING 070936 DAMPENER VIBRATION 070936C DAMPENER VIBRATION 039253 SCREW HHC M8-1.25 X 20 G8.8 022145...

  • Page 35

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. 0A4355 0C1636 036434 036449 0C1330 0C1318 0C1068 0C1412 0A5728 060366 066889 022145 022129 045771 0A8974 Section 7 - Exploded Views and Parts Exploded View – Muffler — Drawing No. 0C1408B DESCRIPTION MANIFOLD EXHAUST 1.5L NIPPLE TOE 1.5 NPT X 6.5 BL IRON...

  • Page 36

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Circuit Breaker — Drawing No. 0A3371B ITEM PART NO. QTY. DESCRIPTION 0A2103 SILKSCREEN "A" PANEL 0A2104 SILKSCREEN "B" PANEL 0A2105 SILKSCREEN "C"...

  • Page 37

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. DESCRIPTION 074100 ASSY HOME STDBY LOGIC (MODELS 921, 863, 865) 076009A PP LOGIC ASM 50/60HZ (MODEL 9428) 072566 NUT SPACER .250 PCB 080882 SCREW PPH TAPPING #6X5/8 SS 074978 DECAL TERMINAL STRIP 047822...

  • Page 38

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Governor Assembly — Drawing No. 0A7216A ITEM PART NO.QTY. DESCRIPTION 098290 ASM MOTOR STEPPER 098941A HOUSING GOVERNOR CONNECTOR 098958A CONNECTOR INTERFACE ASSEMBLY 098942A...

  • Page 39

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. 077483 038804D 038805B 0742600131 022131 046526 052213 059567 078121 022145 022129 022259 050331A 050331 075763 Section 7 - Exploded Views and Parts Exploded View – Battery — Drawing No. 098922E DESCRIPTION BATT 12VDC 75-AH 26 CABLE BATT RED #4 X 20.00...

  • Page 40

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348B 38 Generac Power Systems, Inc. ®...

  • Page 41

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. DESCRIPTION 098671 ASSY ROTOR 10KW 098681 ASSY ROTOR 15KW 098675 ASSY ROTOR 20KW 098936 ASSY ROTOR 25KW 0A5336A HOUSING BLOWER 0A1659 SCREEN AIR OUTLET 071912 SCREW PPHM M5-0.8 X 8 022152...

  • Page 42

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Natural Gas Fuel System — Drawing No. 0A9349E 40 Generac Power Systems, Inc. ®...

  • Page 43

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. 0C2632 075580 026915 039253 022145 022129 045771 0A2666 046747 0C3714 0A5547 0C1475 0A9911 0A7989 0A6593 059402 037561 059403 059401 034154 022152 023897 062522 022127 022259 050280 0A6125 052219...

  • Page 44

    Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642J 42 Generac Power Systems, Inc. ®...

  • Page 45

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators ITEM PART NO. QTY. DESCRIPTION 0A4531 ENGINE-1.5L 035685 CLAMP HOSE #28 1.32 - 2.25 075546A PIPE-FLEX EXHAUST 0A45310258 GASKET-EXHAUST MANIFOLD 0A4355 MANIFOLD-EXHAUST 0A6699 SHIELD HEAT EXHAUST 022097 WASHER LOCK M6-1/4 022507 SCREW HHC 1/4-20 X 1/2 G5 052212...

  • Page 46: Installation Drawings

    Section 8 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 44 Generac Power Systems, Inc. ®...

  • Page 47: Installation Drawings

    Section 8 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 Generac Power Systems, Inc. 45 ®...

  • Page 48

    Section 9 — Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 46 Generac Power Systems, Inc. ®...

  • Page 49

    Section 9 — Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Generac Power Systems, Inc. 47 ®...

  • Page 50: Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.

  • Page 51: Emission Control System Warranty

    Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con- tinue for 24 consecutive months thereafter.

  • Page 52

    Section 9 – Warranty Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators GENERAC’S STANDARD ONE-YEAR LIMITED WARRANTY FOR STANDBY POWER SYSTEMS For a period of one year or 1,500 hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc.

This manual also for:

004128-1, 004130-1, 004131-1, 004475-0

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